EP3145662A1 - Procédé de production de composants céramiques et/ou métalliques - Google Patents

Procédé de production de composants céramiques et/ou métalliques

Info

Publication number
EP3145662A1
EP3145662A1 EP15726558.8A EP15726558A EP3145662A1 EP 3145662 A1 EP3145662 A1 EP 3145662A1 EP 15726558 A EP15726558 A EP 15726558A EP 3145662 A1 EP3145662 A1 EP 3145662A1
Authority
EP
European Patent Office
Prior art keywords
support structure
polymer
mixture
filled
free space
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
EP15726558.8A
Other languages
German (de)
English (en)
Other versions
EP3145662B1 (fr
Inventor
Uwe Scheithauer
Eric SCHWARZER
Claudia POITZSCH
Hans-Jürgen Richter
Tassilo Moritz
Michael Stelter
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Original Assignee
Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV filed Critical Fraunhofer Gesellschaft zur Forderung der Angewandten Forschung eV
Publication of EP3145662A1 publication Critical patent/EP3145662A1/fr
Application granted granted Critical
Publication of EP3145662B1 publication Critical patent/EP3145662B1/fr
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/10—Sintering only
    • B22F3/1017—Multiple heating or additional steps
    • B22F3/1021—Removal of binder or filler
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
    • B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/10—Formation of a green body
    • B22F10/16—Formation of a green body by embedding the binder within the powder bed
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/20—Direct sintering or melting
    • B22F10/28—Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/40—Structures for supporting workpieces or articles during manufacture and removed afterwards
    • B22F10/43—Structures for supporting workpieces or articles during manufacture and removed afterwards characterised by material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F10/00—Additive manufacturing of workpieces or articles from metallic powder
    • B22F10/50—Treatment of workpieces or articles during build-up, e.g. treatments applied to fused layers during build-up
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/004—Filling molds with powder
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/001—Rapid manufacturing of 3D objects by additive depositing, agglomerating or laminating of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
    • B28B11/243—Setting, e.g. drying, dehydrating or firing ceramic articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y80/00—Products made by additive manufacturing
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    • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
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    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/62605—Treating the starting powders individually or as mixtures
    • C04B35/6261—Milling
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    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/05—Metallic powder characterised by the size or surface area of the particles
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    • B22F2003/1042—Sintering only with support for articles to be sintered
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P10/00—Technologies related to metal processing
    • Y02P10/25—Process efficiency

Definitions

  • the invention relates to a method for producing ceramic and / or metallic components. It can be made as pure ceramic, pure metallic or composite / composite components in which areas of metal and other areas of ceramic are formed. In addition, it is possible to form areas of components made of different metals or ceramics.
  • the components are produced by sintering powdery materials.
  • components can be brought by injection molding in molds in the desired shape.
  • the necessary molds are costly, so that an application pays off only for larger quantities.
  • selective laser sintering only a limited density can be achieved with components produced in this way.
  • a support structure enclosing at least one free space is formed with a polymer or polymer mixture.
  • the at least one free space is filled at least in a predefinable area with a plastically deformable or liquid mixture of at least one metal or ceramic powder and at least one organic binder, so that the mixture at least partially rests against the wall of the support structure. It can also be a mixture of metal and
  • Ceramic powder can be used.
  • the mixture is in a state with sufficient strength even with further
  • Treatment increases the temperature while the support structure forming polymer and the remaining binder components of the mixture completely decomposes and sintered the metal and / or ceramic powder.
  • the support structure can be formed by surface or selective application of the uncured viscous polymer to the surface of a support. Subsequently, in a two-dimensional application, a locally defined curing of the polymer by a locally defined energy or
  • Substance carried and then afterwards uncured polymer can be removed.
  • a solvent can be used.
  • polymer not needed for the support structure can be washed out, blown off or sucked off.
  • the order of the polymer / polymer mixture for the support structure can be done by knife coating, rolling, dispensing or printing, which should preferably be achieved in metered form.
  • the polymer can be applied and cured only in areas in which a support structure is to be formed.
  • a selectively locally defined application can be carried out by spraying or by means of a dispenser only in areas in which a support structure is to be formed.
  • the polymer By locally defined irradiation with electromagnetic radiation, the polymer can be cured.
  • a laser beam or a mask which is arranged between a radiation source and the polymer, or another selective radiation source with which a point or line-shaped or spatially resolved irradiation is possible, are used.
  • a locally defined substance input for example, a hardener or crosslinker, possible.
  • the support structure can be formed in a plurality of layers arranged one above the other by layer-wise application.
  • a support structure formed in this way can have a different geometric shape in planes exhibit.
  • channels, undercuts or even cavities can be formed in the later component.
  • the support structure may have buried cavities therein, since thereby the amount of material to be removed and the released
  • Debinding gases can be reduced.
  • At least one mixture, successively following the layered formation of the support structure can also be filled in layers in at least one free space formed.
  • the finest channels / areas within the support structure can be filled with the mixture, in which the mixture would not penetrate at longer flow paths due to its poor flow properties.
  • Support structure at least two mixtures with each other
  • components can be obtained, which may consist of the corresponding powder materials used for the mixtures.
  • an outer shell or a surface region of a component may be formed of a material having other properties than a
  • At least one mixture can be filled in newly formed free spaces, which are also successively formed in several levels in the structure of the support structure and can have different geometrical shapes, dimensions and positions in the component.
  • an auxiliary polymer can be used to precisely set the desired geometries for the two areas. This is in the to be filled
  • auxiliary polymer Free space in the support structure initially created with the auxiliary polymer another support structure, which reduces the free space on the area in which the first mixture is to be filled. After this has been filled in, the auxiliary polymer can be removed and the area remains free, which can then be filled with the second mixture.
  • This process can also be adapted accordingly for more than two mixtures to be filled in a free space.
  • the auxiliary polymer should again be easy to remove, which can be achieved by using suitable solvents and dissolving out.
  • the shrinkage of the powder materials used can be considered. It can be chosen at least approximately the same size.
  • the usable polymers for the support structure should have a
  • Decomposition temperature of at least 250 ° C, preferably of at least 270 ° C and more preferably of at least 300 ° C.
  • a polymer or polymer mixture should be used in which at least one part is decomposed only after reaching the maximum temperature in the first thermal treatment.
  • a sufficient strength can be maintained until the mixture with which the actual component is formed has sufficient strength and the function of the support structure no longer has to be fulfilled.
  • the decomposition can thus be carried out more gently, since in each case only a part of the polymer or polymer mixture decomposes and thus a smaller amount of gases formed is liberated per time.
  • Bisphenol A-glycerol dimethacrylates (BisGMA), tri (ethylene glycol) dimethacrylates (TEGDMA), camphorquinones or ethyl 4 (dimethylamino) benzoates can be used, for example, alone or in a mixture of at least two of these polymers as polymer.
  • polyvinyl alcohol, acrylic latex, the other Polymerdsipersionen each alone or in a mixture thereof for the preparation of
  • Support structure can be used.
  • the viscosity of the polymer used for the formation of the support structure can be adjusted with a solvent for the respective polymer.
  • organic binders for the mixtures for example beeswax, paraffin or pyrollidone or a mixture of these can be used.
  • the usable mixtures should have solids contents of at least 40%.
  • the powders used should have as small as possible particle sizes d 50 , which should be less than 15 ⁇ m for metals and less than 5 ⁇ m for ceramics.
  • the mixtures which can be used in the invention can also be referred to as 3DTP compounds.
  • a ceramic and / or metallic particles and a mixture containing an organic binder should be used which is plastically deformable at normal ambient temperature or the processing temperature. At higher temperatures, it may have a reduced viscosity or even be liquid.
  • Processing temperature can be selected in the range 20 ° C ⁇ 10 ° C and preferably a processing temperature in the range 80 ° C ⁇ 40 ° C.
  • a reduction of the viscosity can also be achieved with acting shear forces.
  • a powder with a mean particle size d 50 of 12.2 ⁇ was homogenized with a mixture of paraffin and beeswax at a solids content of 47% by volume for 2 h in a dissolver. Subsequently, this mixture was at a temperature of 100 ° C in the free space of a frame-shaped
  • the frame-shaped support structure was previously defined locally from BisGMA by stratified order and successively locally locally
  • the mixture formed with the metallic powder and the binder mixture successively layer by layer, in the corresponding by the layered formation of the support structure increasing free space be filled.
  • the temperature was increased to a maximum of 1350 ° C while maintaining a heating rate of 4 K / min and sintered the metal powder.
  • the thermal decomposition of the polymer forming the frame-shaped support structure took place. Up to a temperature of 800 ° C was heated at a heating rate of 15 K / h, as in this temperature range, the remaining organic components contained in the mixture have been removed.
  • the second thermal treatment was carried out in an argon / hydrogen atmosphere.
  • the thus obtained steel material component had a density corresponding to 99.3% of the theoretical density.
  • a corresponding powder of this material with an average particle size d 50 of 0.3 ⁇ at a solids content of 45 vol .-% with a Homogenized mixture of paraffin and beeswax for 72 h in a ball mill.
  • This mixture was in the free space of a frame-shaped support structure, as was used in Example 1, filled.
  • the two thermal treatments were carried out under the same conditions as in Example 1. In a possible sintering of this ceramic but can be dispensed with the argon / hydrogen atmosphere, both thermal treatments were carried out in air. In this case, however, the maximum temperature in the second thermal treatment is to be increased to 1500 ° C.
  • the component obtained from the YSZ had a density corresponding to 99.9% of the theoretical density.
  • This mixture was in the free space of a frame-shaped support structure, as was used in Example 1, filled.
  • Example 2 The two thermal treatments were carried out under the same conditions as in Example 2. When sintered in air, a maximum temperature was maintained at the second thermal treatment of 1600 ° C.
  • the alumina component thus obtained had a density corresponding to 99.2% of the theoretical density.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Manufacturing & Machinery (AREA)
  • Ceramic Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Powder Metallurgy (AREA)
  • Compositions Of Oxide Ceramics (AREA)

Abstract

L'invention concerne un procédé de production de composants céramiques et/ou métalliques dans lequel une structure de support, entourant au moins un espace libre, est formée avec un polymère et dans lequel au moins un espace libre est rempli, au moins dans une zone pouvant être prédéterminée, avec un mélange liquide ou plastiquement déformable d'au moins une poudre métallique ou céramique et d'au moins un liant organique. Selon l'invention, le mélange est placé au moins partiellement sur la paroi de la structure de support. Puis, lors d'un premier traitement thermique, le mélange est amené dans un état ayant une résistance suffisante pour conserver sa forme géométrique, une température à laquelle le polymère qui forme la structure de support conserve sa stabilité dimensionnelle étant maintenue. Puis, la température est augmentée lors d'un second traitement thermique, le polymère formant la structure de support est alors complètement décomposé et la poudre métallique et/ou céramique est frittée.
EP15726558.8A 2014-05-20 2015-05-19 Procédé de production de composants céramiques et/ou métalliques Active EP3145662B1 (fr)

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DE102014209519.0A DE102014209519B4 (de) 2014-05-20 2014-05-20 Verfahren zur herstellung keramischer und/oder metallischer bauteile
PCT/EP2015/060968 WO2015177128A1 (fr) 2014-05-20 2015-05-19 Procédé de production de composants céramiques et/ou métalliques

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GB201500609D0 (en) * 2015-01-14 2015-02-25 Digital Metal Ab Additive manufacturing method, method of processing object data, data carrier, object data processor and manufactured object
DE102017120750B4 (de) * 2017-09-08 2022-07-28 Technische Universität Chemnitz Vorrichtung und Verfahren zur Herstellung eines Bauteils mittels 3D-Multimaterialdruck
DE102018211593A1 (de) 2018-07-12 2019-07-25 Carl Zeiss Smt Gmbh Verfahren zum Herstellen eines Cordierit-Körpers und Cordierit-Körper

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DE3926077A1 (de) * 1989-08-07 1991-02-14 Peter Prof Dr Greil Keramische verbundkoerper und verfahren zu ihrer herstellung
JP2615429B2 (ja) 1994-09-13 1997-05-28 工業技術院長 ３次元立体形状の創成法
US6087024A (en) * 1996-12-17 2000-07-11 Whinnery; Leroy Louis Method for forming porous sintered bodies with controlled pore structure
DE19710671C2 (de) * 1997-03-14 1999-08-05 Daimler Chrysler Ag Verfahren zum Herstellen eines Bauteils sowie Verwendung eines derart hergestellten Bauteils
US5989476A (en) 1998-06-12 1999-11-23 3D Systems, Inc. Process of making a molded refractory article
DE10248888B4 (de) * 2002-10-18 2005-01-27 Forschungszentrum Jülich GmbH Verfahren zur Herstellung endkonturnaher, metallischer und/oder keramischer Bauteile
US7700016B2 (en) * 2005-08-02 2010-04-20 Solidscape, Inc. Method and apparatus for fabricating three dimensional models
DE102007003192B4 (de) * 2007-01-15 2012-04-26 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Keramischer und/oder pulvermetallurgischer Verbundformkörper und Verfahren zu seiner Herstellung
US8940224B2 (en) * 2007-12-14 2015-01-27 Cornell University Thermally stable crystalline mesoporous metal oxides with substantially uniform pores
KR102021406B1 (ko) * 2011-06-01 2019-09-16 밤 분데스안슈탈트 퓌어 마테리알포르슝 운트-프뤼풍 성형체를 제조하기 위한 방법 및 장치
WO2014186769A1 (fr) * 2013-05-17 2014-11-20 Uram Stuart Moules de coulage céramique
JP6390108B2 (ja) * 2014-02-07 2018-09-19 セイコーエプソン株式会社 焼結造形材料、焼結造形方法、焼結造形物および焼結造形装置

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DE102014209519A1 (de) 2015-11-26
DE102014209519B4 (de) 2018-10-18
US20170182554A1 (en) 2017-06-29
EP3145662B1 (fr) 2018-10-17
WO2015177128A1 (fr) 2015-11-26

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